GB1592495A

GB1592495A - Method of producing tiles

Info

Publication number: GB1592495A
Application number: GB48895/77A
Authority: GB
Original assignee: Karlsson K U B
Current assignee: Karlsson K U B
Priority date: 1976-12-06
Filing date: 1977-11-24
Publication date: 1981-07-08
Also published as: DE2752628A1; SE7613655L; SE405136B; FR2372699A1

Description

(54) METHOD OF PRODUCING TILES (71) I, KJELL UNO BÖRJE KARLSSON, a Swedish Subject of Harstena Lycke 2160, S- 382 00 NYBRO, Sweden, do hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement: The present invention relates to a method for the production of roof or wall tiles.

Traditional roofing materials in tile form generally require the use of boarding, that is to say total covering of the roof surface with boards, in order to render the roof completely weatherproof, a layer of roofing felt or the like normally being nailed onto the boards before the tiles are put in place, which entails considerable costs. Such roofing materials often consist of clay, concrete or eternite tiles, whose colour and shape can be varied within certain limits but whose use imposes a great restriction on design.

Facade covering also requires a stable and compact substrate and is often also required to provide insulation.

The object of the present invention is to produce tiles which are self-supporting so that the supporting substrate is eliminated and which may be joined together so that the risk of leakage is totally eliminated, thus dispensing with the need for roofing felt or the like in a roof covering operation. An important aspect of the present invention is to produce the tiles such that they do not collect water which, in the event of frost, can freeze and destroy the coating on the tiles, and such that weather conditions including solar radiation will not otherwise negatively affect the coating on the tiles.

A further aspect of the present invention is to make possible variation of the arrangement of the tiles within broad limits.

It is generally known to produce tiles which comprise a base manufactured from resin and reinforcing materials, in which base decorative materials, for example crushed marble or other mineral material, is anchored by being pressed in place. Such a material does not satisfy the requirements which form the basis of the present invention, in particular in use as a roof covering.

The present invention provides a method of producing tiles which comprises impregnating a flexible reinforcing layer with a liquid mixture of resin and resin-curing additives, partially curing the resin to tacky-dryness to form a composite layer having less flexibility than the unimpregnated reinforcing layer, coating the composite layer with a liquid mixture of resin and resin-curing additives to form thereon a further layer having a desired surface structure, and completely curing the resin of the composite layer and the further layer to produce a tile having less flexibility than the partially cured composite layer.

In the production of comparatively thin elements, the reinforcing layer may consist of one or more layers of a glass fibre mat or a wire mesh or a textile mat. The reinforcing layer can, however, also be formed by an outer surface layer of an insulating mat, and the resultant tile may then be used to finish an outer wall unit. The further layer can be formed using a smooth or profiled roller to obtain the desired surface structure.

The further layer can comprise many different particulate minerals and metals, fibres etc., so as to present a decorative appearance.

It can, however, also form an intermediate layer which is covered by surface material, for example a dry powder, a metal foil, chips, reeds or straw prior to final curing.

In the production of the tiles, the further layer is provided preferably such as to leave regions free of the further layer forming flanges along two adjacent side edges of each tile, the joint flanges being capable of accomodating sealant which unites with the resin material.

Resin material which is not resistant to solar radiation may, before use, be UV-stabilized.

The invention also relates to a tile manufactured in accordance with the above-indicated method.

The present invention will be more clearly apparent from the accompanying drawings, which illustrate embodiments of the invention.

In the accompanying drawings: Figure 1 shows, from above, a corner portion of a tile produced according to the present invention; Figure 2 is a section taken along the line 11-11 in Figure 1; II-II in Figure 1; Figure 3 shows another embodiment of a tile according to the invention; Figures 4 and 5 illustrate, from the side, the jointing together of tiles according to the present invention; Figure 6 shows another type of tile according to the invention; and Figure 7 illustrates a production line with conveyor belts for carrying out a method in accordance with the invention.

Referring to Figures 1 and 2, a roof tile 10 comprises a substrate sheet 11 consisting of a reinforcing layer of glass fibre, rags, steel wire or other suitable material which has been impregnated with suitable resin or plastics material, for example, polyester. The sheet is rectangular, suitably square, has a thickness of from 2 to 3 mm and is self-supporting. On the greater part of its surface the sheet 11 has a coating layer 12 which can include crushed mineral, swarf, straw material, reed or hay etc. A region of a predetermined width extends along two adjacent edges, this region being, for the purposes of forming joint flanges 13, devoid of coating. As will be apparent from the following description, the coating layer 12 also incorporates resin by means of which it is anchored to the substrate sheet 11. A number of elongate holes 14 are provided in the joint flanges 13.A glue joint 15 is provided between the edges of the coating layer 12 which border the joint flanges 13 and the holes 14, the glue joint consisting of a conventional glue strand or, as is shown in Figure 4, of a rubber or plastics strand 16 with a baked-in resistor wire which, on connection to a suitable power source, heats the rubber or plastics strand to the liquid state for uniting with the substrate sheet 11. The tiles of Figures 3 to 6 are of generally similar construction to the tile of Figures 1 and 2.

A tile of the above-described type is produced in the following manner.

An endless, driven silicone rubber belt 21 is supplied at its one end with a glass fibre mat 22 and a woven glass cloth 23. Resin in the form of UV-stabilized polyester is applied to the belt 21 from a supply funnel 24, as are accelerator and catalyst from supply funnels 25 and 26, and is spread over the belt by means of a level roller 28 under vibration by means of a vibrator 27 for preventing the enclosure of air.

The belt 21 has raised edges which prevent the resin from running out over the belt sides. The spread-out resin layer is then cured to the tackydry state by means of a radiation device 29 which emits infra-red light. The resultant composite layer forms the substrate sheet 11.

To a mixer 20 are added the following materials: coating material, in the form of crushed mineral, from a supply funnel 30; resin, in the form of UV-stabilized polyester with accelerator and catalyst from supply funnels 31, 32 and 33;and pigment from a supply funnel 34. These materials are mixed intensively in the mixer 20 and are then applied to the tacky-dry resin substrate sheet 11 on the belt 21 during vibration by means of the vibrator 35 whereby the layer is spread out.

After the application of the coating layer 12, partial curing is effected by means of a radiation device 36 of the same type as the device 29, the layer being then worked by means of a roller 37 which is either smooth or has a surface pattern for structuring the coating layer.

The thus produced tile may now be finally cured in an oven 39 with temperature zones 40, 41, and 42 whose temperatures are 60"C, 120"C and 60"C respectively, in which case the coating layer also forms the decorative outer layer. However, it is also possible, prior to the curing in the oven 39, to apply, at 38, a surface layer, for example in the form of a dry powder, a metal foil or natural material, which will adhere to the coating layer because of its tacky nature.

After the final curing in the oven 39, loose material is removed at stage 43, whereupon the glue joint 15 or the rubber or plastic strand 16 is applied at 44. The web is thereafter cut at 45 by means of a cutter (not shown) and is conveyed off across a table 46.

If the tiles have joint flanges 13, the coating and surface layers will, naturally, not be spread out across the entire substrate sheet 11, a region along one of the longitudinal edges being kept free from coating and surface material.

For producing the second joint flange at right angles to the first it is, for example, possible to arrest momentarily the supply of the coating material from the mixer 20 or to provide a device, between the radiation device 36 and the mixer 20, extending across the entire belt width and being arranged to be lowered and to remove coating material in a transverse region.

Naturally, the material used in the tile production can be varied within broad limits.

Apart from glass fibre, the reinforcing material can consist of metal or textiles. It has proved to be particularly advantageous to use, for the reinforcing layer, a surface layer of an insulation mat, so that the rear face of the tile is automatically provided with an insulation layer. In such a case, it is also possible, by a special design of the belt 21, to produce profiles on the underside of the substrate sheet 11, for example flanges extending along the longitudinal edges and projecting at right angles from the underside, the insulation layer extending between the flanges. Like the reinforcing material, the resin material can be varied; the main factor to keep in mind is that this resin material must not be negatively affected by the weather. A considerable number of materials, such as minerals, metals, fibres etc., can be used as the coating material and, similarly, many different materials can be used as the surface material, as desired. Profiling can be effected in the manner illustrated in Figure 7 but it is also possible to profile the belt 21 for obtaining the desired pattem.

After the above-described manufacture of the tiles 10, fixing holes 14 are made in the joint flanges 13 and the glue joint 15 or rubber or plastics strand 15 is applied, which, however, can also be effected in conjunction with the above-described tile production.

Figure 3 shows a roof tile 10 whose coating layer 12 has been structured into a conventional appearance. The tile 10 in Figure 6 has also a coating layer 12 with a conventional pattern, but here the tile 10 has, on its underside, an insulation layer 19 which extends between the roof trusses 18 and is, on its underside, provided with a coating which forms a ceiling. A pattern similar to that of the roof surface in Figure 6 can be obtained by fixing chips to the coating layer 12 instead of profiling it.

The above-described tile is used, as was mentioned earlier, advantageously as a roof covering; boarding being, in this case, unnecessary; merely battening being required with a centre spacing between each successive batten in the longitudinal and transverse directions corresponding to the distance between the fixing holes 14 of two adjacently placed tiles 10. The laying of the tiles is carried out as will be described with reference to Figures 4 and 5.

Once a tile has been nailed into place with nails 17, the next tile to be laid is arranged in place with an edge lacking a joint flange above a joint flange 13 of the first tile, as shown in Figure 4, keeping a small joint space between the edges of the tiles facing each other, the second tile being nailed in this position. Once a row of tiles has been nailed in place across the entire length of the roof, the next higher layer is laid out in a corresponding manner, and so on.

The tight sealing of one tile 12 with its two adjacent tiles in the row is effected, as has been intimated above, preferably by means of the joint strand 15, made of polybutadiene rubber for example, shown in Figure 4 with the bakedin resistor wire 16. This is effected by coupling together the resistor wires 16 of a predetermined number of tiles in series or in parallel and connecting them to a power source, for example a 12V transformer. By means of the wires 16 the rubber is caused to melt and then run out into the joints between the tiles 12, in the manner illustrated in Figure 5, and adheres to the tile surfaces defining the joints. In this way, a tight, reliable joint is obtained.However, the tiles can be sealed with respect to each other by means of a conventional glue joint, for example, consisting of a strand of suitable plastics material which can be covered with a protective paper which is ripped off in conjunction with the laying of the tiles.

One advantage inherent in the present invention is that the coating or surface layer can consist of reeds, chips or straw, whereby it is possible in a simple manner to impart to the roof a more old-fashioned appearance which, because of the fire risk and, for example, thatching costs, is seldom seen nowadays.

Naturally, concerning the fire risk, the plastic materials included in the roof covering tile according to the invention should be fire-proof and self-extinguishing as well as being resistant to aging and preferably stabilised with respect to ultra-violet radiation. The movement which occurs in the roof covering is easily accomodated by means of the elongate fixing holes 14 and the resilient plastic material in the joints between the tiles. A further advantage with the roof covering tile according to the invention is that the lowermost tile can, without problem, be designed such as to form a gutter, and similarly the tiles located closest to the gables can be given such a shape that, for example, barge boards are rendered unnecessary.

An economic calculation has shown that, by using roof covering tiles according to the invention, it is possible to reduce roof covering costs by about 50%.

WHAT I CLAIM IS: 1. A method of producing tiles which comprises impregnating a flexible reinforcing layer with a liquid mixture of resin and resin-curing additives, partially curing the resin to tackydryness to form a composite layer having less flexibility than the unimpregnated reinforcing layer, coating the composite layer with a liquid mixture of resin and resin-curing additives to form thereon a further layer having a desired surface structure, and completely curing the resin of the composite layer and the further layer to produce a tile having less flexibility than the partially cured composite layer.

2. A method according to claim 1, wherein the reinforcing layer consists of at least one glass fibre mat.

3. A method according to claim 1, wherein the reinforcing layer is formed by a surface layer of an insulating mat.

4. A method according to any one of claims 1 to 3, wherein the further layer is formed using a smooth roller.

5. A method according to any one of claims 1 to 3, wherein the resin for forming the further layer is first partially cured and the further layer is then formed by using a profiled roller.

6. A method according to any one of the preceding claims, wherein a surface material is applied to the further layer prior to the final curing of the resin therein.

7. A method according to claim 6, wherein the surface material is a dry powder.

8. A method according to claim 6, wherein the surface material is a metal foil.

9. A method according to claim 6, wherein the surface material consists of chips, reeds or straw.

10. A method according to any one of the preceding claims, wherein the tiles are produced as a continuous web on an endless conveyor belt with stations for the supply of the different materials and for resin curing posi

**WARNING** end of DESC field may overlap start of CLMS **.

Claims

**WARNING** start of CLMS field may overlap end of DESC **. profile the belt 21 for obtaining the desired pattem. After the above-described manufacture of the tiles 10, fixing holes 14 are made in the joint flanges 13 and the glue joint 15 or rubber or plastics strand 15 is applied, which, however, can also be effected in conjunction with the above-described tile production. Figure 3 shows a roof tile 10 whose coating layer 12 has been structured into a conventional appearance. The tile 10 in Figure 6 has also a coating layer 12 with a conventional pattern, but here the tile 10 has, on its underside, an insulation layer 19 which extends between the roof trusses 18 and is, on its underside, provided with a coating which forms a ceiling. A pattern similar to that of the roof surface in Figure 6 can be obtained by fixing chips to the coating layer 12 instead of profiling it. The above-described tile is used, as was mentioned earlier, advantageously as a roof covering; boarding being, in this case, unnecessary; merely battening being required with a centre spacing between each successive batten in the longitudinal and transverse directions corresponding to the distance between the fixing holes 14 of two adjacently placed tiles 10. The laying of the tiles is carried out as will be described with reference to Figures 4 and 5. Once a tile has been nailed into place with nails 17, the next tile to be laid is arranged in place with an edge lacking a joint flange above a joint flange 13 of the first tile, as shown in Figure 4, keeping a small joint space between the edges of the tiles facing each other, the second tile being nailed in this position. Once a row of tiles has been nailed in place across the entire length of the roof, the next higher layer is laid out in a corresponding manner, and so on. The tight sealing of one tile 12 with its two adjacent tiles in the row is effected, as has been intimated above, preferably by means of the joint strand 15, made of polybutadiene rubber for example, shown in Figure 4 with the bakedin resistor wire 16. This is effected by coupling together the resistor wires 16 of a predetermined number of tiles in series or in parallel and connecting them to a power source, for example a 12V transformer. By means of the wires 16 the rubber is caused to melt and then run out into the joints between the tiles 12, in the manner illustrated in Figure 5, and adheres to the tile surfaces defining the joints. In this way, a tight, reliable joint is obtained.However, the tiles can be sealed with respect to each other by means of a conventional glue joint, for example, consisting of a strand of suitable plastics material which can be covered with a protective paper which is ripped off in conjunction with the laying of the tiles. One advantage inherent in the present invention is that the coating or surface layer can consist of reeds, chips or straw, whereby it is possible in a simple manner to impart to the roof a more old-fashioned appearance which, because of the fire risk and, for example, thatching costs, is seldom seen nowadays. Naturally, concerning the fire risk, the plastic materials included in the roof covering tile according to the invention should be fire-proof and self-extinguishing as well as being resistant to aging and preferably stabilised with respect to ultra-violet radiation. The movement which occurs in the roof covering is easily accomodated by means of the elongate fixing holes 14 and the resilient plastic material in the joints between the tiles. A further advantage with the roof covering tile according to the invention is that the lowermost tile can, without problem, be designed such as to form a gutter, and similarly the tiles located closest to the gables can be given such a shape that, for example, barge boards are rendered unnecessary. An economic calculation has shown that, by using roof covering tiles according to the invention, it is possible to reduce roof covering costs by about 50%. WHAT I CLAIM IS:

1. A method of producing tiles which comprises impregnating a flexible reinforcing layer with a liquid mixture of resin and resin-curing additives, partially curing the resin to tackydryness to form a composite layer having less flexibility than the unimpregnated reinforcing layer, coating the composite layer with a liquid mixture of resin and resin-curing additives to form thereon a further layer having a desired surface structure, and completely curing the resin of the composite layer and the further layer to produce a tile having less flexibility than the partially cured composite layer.

7. A method according to claim 6, wherein the surface material is a dry powder.

8. A method according to claim 6, wherein the surface material is a metal foil.

tioned along the belt.

11. A method according to any one of the preceding claims, by which rectangular tiles are produced, wherein regions along two adjacent sides of the tile are kept free from the further layer so as to form joint flanges.

12. A method according to claim 11, wherein a sealant strand is provided along the joint flanges, the strand being unifiable with the impregnated reinforcing layer by the application of heat and/or pressure.

13. A method according to claim 12, wherein the sealant strand has a resistor wire which may be connected to a source for heating of the strand material and unification thereof with the impregnated reinforcing layer.

14. A method according to claim 12 or 13, wherein the sealant strand is manufactured from polybutadiene rubber.

15. A method according to any one of the preceding claims, wherein the resin material employed is UV-stabilized.

16. A tile produced in accordance with any one of the preceding claims.

17. A method of producing tiles, substantially as hereinbefore described with reference to the accompanying drawings.

18. A tile produced according to the method substantially as hereinbefore described with reference to the accompanying drawings.